The purpose of this section is to assemble a basic lamp. This will provide
a familiarity with some basic household electrical hardware. While the
lamp is a fairly simple electrical device, all of the assembly steps must
be executed in the proper fashion. Failure to do so may lead to a hazardous
situation.

IMPORTANTDo not attempt to plug in your lamp at anytime during this exercise.It must first be checked by an instructor.The lamp is to be plugged-in and tested only by an instructor or
TA and only at the designated testing location.

Wiring the plug.

1. Locate the plug.

2. Unscrew the two screws next to the prongs that hold the plug together.
Do not lose the screws. Pull the plug apart and set the components aside.

3. Locate the brown line cord (this type of wire is also called zip
cord or lamp cord).

4. On one end, separate the wire as shown in Figure
1. Use the orange razor knife to start the split. Be careful the
knife is sharp. Always cut away from yourself. Use the cardboard as a cutting
surface. Do not cut directly on the table. Separate about 2 inches
of wire.

5. Tie the underwriter’s knot in the wire as shown in Figure
2 and on the chalk board in the front of the room.

6. After tying the knot, use the wire cutters to cut the wires so about
1 inch is left after the knot.

7. Use the red wire strippers to remove 1/2 to 3/4 inch length of insulation
from each of the two wires on one end of the cord. See Figure
3. There should be an extra piece of wire in the tool box on which
you can practice using the wire strippers.

9. Twist each wire so the wire strands are tightly packed (as in Figure
3). It is important to twist all of the fine strands into a tightly
packed bundle. Loose wires can cause a short circuit.

10. Using the pliers, bend a small loop in the wire (refer to Figure
4). It is preferable to use pliers rather than your fingers. Using
pliers it is possible to make a neat loop.

11. Loosen the screws on the prongs of the plug. Continue turning them
out until they stop but do not force them all of the way out.

12. Put the hook of wire around the screw. Put the wire on so the hook
faces in a clockwise direction. In this way tightening the screw also
tightens the loop. Tighten screw to secure the wire. This step is illustrated
in Figure 5.

13. Make sure there are not any loose strands. If there are loose
strands, remove wire, twist strands together and reconnect.

14a. Attach the other wire to the other prong as above.

DO NOT reassemble the plug yet! Have the plug checked and obtain
initials below.

14b. Reassemble plug. To do this, push the prongs into the plug housing
(as shown in Figure 6). The wire should fit neatly
into the plug housing. Secure the housing by using the two small screws
that you removed earlier.

Wiring the Lamp Socket

15. Locate lamp socket. Open socket by pressing and pulling on upper
part where it is marked "Press." Identify the parts as shown in Figure
7.

16. Separate 2 1/2 inches of cord on end and put through center tube
and base as shown in Figure 8.

17. Tie the underwriters knot. This is illustrated in Figure
7 or on the chalk board in the front of the room. Look closely at Figure
7, make sure the wire goes through the base plate BEFORE you tie
the knot.

18. Strip off the insulation from 1/2 to 3/4 inch from the end of each
wire. Twist strands of each wire into a tight bundle. Use the pliers to
form a half-loop in each wire.

19. Loosen the terminal screws on the lamp socket. Do not force the
screws all of the way out.

20. Wrap one wire around each terminal screw in clockwise direction
and tighten screws. This is shown in Figure 7.

21. Make sure there are not any loose strands. If there are loose strands,
remove wire, twist strands together and reconnect.

22. Before final assembly have lamp socket checked and obtain initials
below.

23. Reassemble lamp socket. The wire should fit neatly into the bottom
of the socket.

24. Once lamp has been checked and assembled, bring to testing station
to be checked.